65 A - Valeo version with poly V-belt drive — VW

65 A - Valeo version with poly V-belt drive
1
Hexagon nut
40 Nm
2
Washer
3
Belt pulley
Diameter 70 mm.
Removing and installing
Fig.
.
4
Spacer
5
Washer
6
Fan gear
Note direction of rotation, marked by arrow
7
Washer
8
Intermediate ring
9
Bearing plate
Marking position relative to alternator housing
10
Ball bearing (drive side)
Removing and installing
Fig.
.
11
Securing ball bearing
12
Intermediate ring
13
Semi-round key
14
Rotor
Checking earth connection
Fig.
Checking winding short or open circuit
Fig.
15
Ball bearing (slip ring side)
Removing and installing
Fig.
.
16
Stator
Removing and installing
Fig.
.
Checking earth connection
Fig.
Checking open circuit
Fig.
17
Metal ring
18
Plastic bush
Always use new bush
19
Alternator housing
20
Cover
21
Diode plate
Removing and installing
Fig.
.
Checking
Fig.
22
Voltage regulator
Removing and installing
Fig.
.
23
Stud
Securing, tensile relaxation of B+ and D+ wires, 3 Nm
24
Decoupling capacitor
2.2 mF, 110 V
Decoupling capacitor connection
Plug B+
arrow
Removing and installing voltage regulator
The voltage regulator can be removed without removing the alternator.
Alternator carbon brushes
Length of new carbon brushes: 12 mm
Wear limit: 5 mm
Relative tolerance: +1 mm
Removing and installing ball bearing
1
Removal device, e.g. Kukko 15/0 or 17/0
2
Puller, e.g. Kukko 18/0
Note
When installing, press ball bearing through inside ring up to stop.
Always use new bearing.
Removing and installing belt pulley.
Hold belt pulley fast with strap wrench.
Unscrew hexagon nut.
Tighten threaded connections to specified torque settings
Chapter
.
Rotor - checking earth connection
Press button for resistance measurement on
hand multimeter
V.A.G 1526 B
.
An arbitrary resistance value must flash in the kΩ measurement range.
Rotor - checking winding short or open circuit
Press button for resistance measurement on
hand multimeter
V.A.G 1526/B
.
Resistance: 2.8 to 3.0 Ω
Open circuit: An arbitrary resistance value flashes in the kΩ measurement range.
Winding short circuit: Resistance value is not attained.
Removing and installing stator and diode plate
Use needle-nose pliers to dissipate heat at the soldering points
arrows
.
Use radio solder and max. 300 W soldering iron.
Desolder stator windings.
Stator - checking earth connection
Press button for resistance measurement on
hand multimeter
V.A.G 1526/B
.
Connect measuring cables consecutively to measuring points at 1 and 2; 1 and 3; 1 and 4.
An arbitrary resistance value must flash in the kΩ measurement range.
Stator - checking open circuit
Press button for resistance measurement on
hand multimeter
V.A.G 1526/B
.
Route measuring lines consecutively to winding ends at 1 and 2; 1 and 3; 2 and 3.
The gauge must indicate approximately 0 ohms at each measurement.
In case of an open circuit an arbitrary resistance value must flash in the kΩ measurement range.
Checking diode plate
Simultaneously press buttons for resistance and voltage measurement on
hand multimeter
V.A.G 1526 B
.
Check positive diodes: consecutively connect black terminal to positive heat sink
1
(corresponds to B+) and red terminal to collective points
2
.
Check negative diodes: consecutively red terminal to negative heat sink
3
and black terminal to collective points
2
.
Check exciter diodes: consecutively black terminal to contact rail
4
(corresponds to D+) and red terminal to collective points
2
.
All tests must indicate 50 - 80 Ω 3 times; renew diode plate in case of deviation.